Catalyst support assembly for a contact lens sterilizing apparatus

ABSTRACT

Apparatus is provided for use in the sterilization of contact lenses or the like, wherein lenses are disposed within a sterilizing solution contained within a reaction vessel, which sterilizing solution is capable of being decomposed through contact with a catalytic agent. The apparatus comprises a reaction vessel capable of containing a sterilizing solution and comprising a container portion, a cover and structure for supporting an article in contact with sterilizing solution in the container. Further structure is provided for mounting a catalytic agent on the supporting structure such that the catalytic agent is removable for replacement by a user as the catalytic agent becomes exhausted in use. The mounting of the catalytic agent on the article supporting structure prevents contact of the catalytic agent with the solution in the container until the article supporting structure with the contact lenses therein is placed in the solution in the container for beginning the sterilizing process, to thereby prevent premature breakdown of the sterilizing solution prior to the introduction of contact lenses for sterilization therein.

This is a divisional of copending application(s) Ser. No. 07/631,759filed Dec. 21, 1990, now U.S. Pat. No. 5,196,174 which is a File WrapperContinuation of Ser. No. 07/364,471 filed on Jun. 9, 1989, nowabandoned.

BACKGROUND OF THE INVENTION

This invention relates to a chemical sterilization process for articlessuch as contact lenses. More particularly, the invention concerns animproved apparatus adapted to be employed in said chemical sterilizationprocess.

The sterilization of contact lenses is currently done by a number ofdifferent processes. Some processes employ heat, either in a drysterilization environment, or with a sterilized saline or similarsolution. A further process has also been developed which employs ananti-microbial sterilizing solution such as hydrogen peroxide (H₂ O₂).

The present invention concerns an apparatus specifically designed foruse with the latter (hydrogen peroxide) type of sterilization technique.One particularly useful method and apparatus is disclosed in prior U.S.Pat. No. 4,013,410, also assigned to the assignee of this application,to which reference is invited for background material concerning thistype of sterilizing process.

Briefly, the hydrogen peroxide solution which is employed is of arelatively weak concentration, for example, no more than on the order of3% solution of hydrogen peroxide in water. In this sterilizing processit is important to insure that the hydrogen peroxide solution, or anyremnants thereof, are completely absent from the lenses before thelenses are reinserted by the wearer. Accordingly, the heretofore appliedprocesses operate to neutralize the hydrogen peroxide solution wellbefore the lenses are removed from the apparatus and replaced in the eyeof the wearer.

Generally speaking, the process employed by the above referenced patentuses a catalytic agent such as platinum, which will produce a chemicalreaction resulting in neutralization or decay of the hydrogen peroxide.Essentially, a free oxygen molecule is liberated and the hydrogenperoxide is reduced to water. Preferably, the process is arranged totake place over a period of several hours of time, depending on thenature of the catalytic agent and the initial strength of the originalsterilizing solution. Accordingly, it is generally recommended that theuser employ the process overnight in order to assure full decompositionof the hydrogen peroxide and a considerable period of soaking of thelenses in the sterile water which remains of the solution afterdecomposition of the hydrogen peroxide.

While the apparatus employed in the above-referenced patent has met withcommercial success, there is nonetheless room for further improvement.More particularly, one apparatus currently in use employs a plasticcarrier member which is coated with a suitable platinum catalytic agent,and which is generally disposed in the bottom of a cylindricalcontainer. The container is then filled with the hydrogen peroxidesolution and the contact lenses, which are held in a further lenscarrier/lens support case member, are then disposed within thecontainer. Generally speaking, the lens support or lens carrier membersare well-ventilated basket-like structures which are affixed to a capmember which in turn forms a cap or top closure for the solution-filledcontainer. It is important, however, to provide some venting of the capportion of the closure to control pressure buildup by permitting theescape of some of the free oxygen generated during the decomposition ofthe hydrogen peroxide solution.

While this system has proven highly successful in operation, there is,as mentioned above, room for improvement. For example, it is necessaryfor the user to periodically handle the "catalyst" which has the coatingof catalyst material. That is, the catalyst material is consumed over aperiod of use, and therefore the catalyst member must be removed andreplaced with a new catalyst from time to time. Handling by the consumerhas a number of drawbacks. Some of the platinum coating of the carriermay rub off onto the fingers and cause undesirable staining of the skinand/or clothing of the user. Moreover, various proteins, salts, etc.,from the skin might compromise the integrity and action of the catalyst.It appears that to some extent sulfur compounds and the proteins in theskin may combine with the platinum to form an inert compound. Moreover,with the catalyst member disposed in the bottom of the container, it issomewhat difficult to reach it manually without the use of some sort oftool, or the like.

There is also some concern that with the catalyst sitting in the bottomof the container between uses and after rinsing the container followinga use, that some excess water may be trapped or entrained around thecatalyst member which may give some potential for bacterial growth.

OBJECTS AND SUMMARY OF THE INVENTION

It is an object of the invention to provide an improved apparatus foruse in the foregoing lens sterilization process which further improvesupon some of the prior art apparatus discussed hereinabove.

Briefly, and in accordance with the foregoing discussion, the inventionprovides apparatus for use in the sterilization of contact lenses or thelike, wherein said lenses are disposed within a sterilizing solutioncontained within a reaction vessel, which sterilizing solution iscapable of being decomposed through contact with a catalytic agent. Theapparatus in accordance with the invention comprises a reaction vesselcapable of containing a sterilizing solution and comprising a containerportion, cover means and means for supporting an article in contact withsterilizing solution in said container; and further including means formounting a catalytic agent on said supporting means such that saidcatalytic agent is removable for replacement by a user as the catalyticagent becomes exhausted in use; said mounting of said catalytic agent onsaid supporting means thereby preventing contact of the catalytic agentwith the solution in said container until the article supporting meanswith the contact lenses therein are placed in the solution in thecontainer for beginning the sterilizing process, to thereby preventpremature breakdown of the sterilizing solution prior to theintroduction of contact lenses for sterilization therein.

BRIEF DESCRIPTION OF THE DRAWINGS

The features of the present invention which are believed to be novel areset forth with particularity in the appended claims. The organizationand manner of the operation of the invention, together with furtherobjects and advantages thereof may best be understood by reference tothe following description, taken in connection with the accompanyingdrawings in which like reference numerals identify like elements, and inwhich:

FIG. 1 is a partially exploded perspective view of apparatus inaccordance with the invention;

FIG. 2 is an enlarged sectional view of a fully assembled apparatus ofthe invention in operation for sterilizing contact lenses;

FIG. 3 is a reduced sectional view taken generally along the line 3--3of FIG. 2;

FIG. 4 is an enlarged exploded perspective view illustrating aframe-like carrier member and a disc-like catalyst member in accordancewith a preferred form of the invention;

FIG. 5 is a transverse section taken on the assembled carrier andcatalyst members of FIG. 4;

FIG. 6 is an enlarged partial sectional view of a cover portion of alens carrier and support portion of the apparatus of the invention,showing the cover in a closed position;

FIG. 7 is a sectional view similar to FIG. 6 and showing an intermediateposition of the cover portion thereof in full line and a fully openposition thereof in phantom line;

FIG. 8 is an exploded perspective view illustrating the assembly of thecatalyst member and carrier member with the lens support assemblyutilizing a specialized tool in accordance with an alternate form of theinvention;

FIG. 9 shows a further step in the assembly indicated in FIG. 8;

FIG. 10 is an enlarged partial perspective view of a portion of the lenssupport structure in accordance with a preferred form of the invention;

FIG. 11 is a sectional view taken generally along the line 11--11 ofFIG. 10;

FIG. 12 is a partially exploded elevational view showing an alternateform of catalyst member and catalyst carrier portion of the lens carrierand support assembly, in accordance with an alternate form of theinvention;

FIG. 13 is an exploded perspective view indicating assembly of thecatalyst, lens carrier and container portion in accordance with theembodiment of FIG. 12; and

FIG. 14 is a bottom plan view showing the catalyst member configured inaccordance with FIGS. 12 and 13 assembled with the lens carrierassembly.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENT

Referring initially to FIGS. 1-3, the apparatus in accordance with theinvention is designated generally by the reference numeral 20. Generallyspeaking, the apparatus 20 includes a container or reaction vessel 22,which is preferably generally cylindrical in shape and terminates in anopen top 24 which preferably has a thread 26 formed thereupon forthreadably engaging a complementary thread 28 formed within a cap member30. This reaction vessel or container 22 is particularly adapted tocontain a quantity of sterilizing solution 32, which preferablycomprises hydrogen peroxide. In accordance with prevailing practice, thehydrogen peroxide is of a relatively low concentration, and preferablyno more than a 3% solution of hydrogen peroxide in water. Differentconcentrations of hydrogen peroxide may be used in particularapplications without departing from the invention.

In accordance with the customary practice, the cap member 30 also mountsa lens supporting structure or assembly designated generally by thereference numeral 40. The lens supporting structure 40 comprises a pairof basket-like lens-receiving or lens support structures 42, 44 whichare substantially identical and oppositely facing. Each lens supportingstructure comprises a base 43, 45 which includes a lens-supportingdome-like or semi-spherical member or portion 46, 47 and an overlyingand complementary formed basket-like lid member 48, 49 which ispreferably hingedly attached to a base or frame portion 50 from whichthe aforementioned lens support members 46, 47 projects.

Preferably, both the cover member 48, 49 and the lens support member orportions 46, 47 are formed of a lattice-like structure to promote flowof the fluid 32 therethrough and around contact lenses 52, 53 disposedtherebetween when the cap 30 and depending lens support structure 40 arecoupled with the container or reaction vessel 22. In this regard, itwill be seen that the cap and lens support structure 30, 40 areillustrated in an inverted position in FIG. 1, such that in use thestructure of FIG. 1 is inverted such that the threads of the cap 30engage the threads 26 of the container 22 and such that the contactlenses, as indicated for example by reference numeral 52, are supportedin a position depending from the cap and immersed within the fluid 32 inthe container 22. Most of the foregoing structure is conventional inform, and need not be described in further detail herein.

Departing from convention, and in accordance with an important featureof the invention, the lens support or lens carrying structure 40 isfurther provided with an open-ended central interior receptacle orchamber 60. Within this receptacle 60 there is received a catalyticagent indicated generally by reference numeral 62 in a positionsubstantially intermediate the contact lenses, e.g., 52, 53 supportedwithin the basket-like structures defined by projection 46 andbasketlike cover member 48. The mounting of the catalyst member 62 inthis fashion substantially precludes any physical contact of the userwith the catalytic agent during use; however, as will be seen later, thecatalytic agent or catalyst member 62 is easily removable andreplaceable when desired, as for example, when replacing a catalyticagent which has become exhausted from use.

Advantageously, the placing of the catalyst member or catalytic agent 62within the lens support structure in this manner achieves two importantends. Firstly, this arrangement substantially prevents contact of thecatalyst material by the user, thereby preventing any undesirable effecton the catalyst, for example the formation of an inert compound on thecatalyst agent as a result of contact with sulfur compounds and proteinsin the skin. As a second important matter, the placement of the catalystor catalytic agent in the lens carrying structure prevents the catalystfrom coming into contact with the solution 32 until the user hascompleted the placement of the lenses within the lens support structure,inverted the cap and lens support structure, and placed the same withinthe container 22 to begin the sterilization process.

In some prior art apparatus, a catalyst member is placed directly intothe container 22, thus beginning the breakdown of the sterilizingsolution prior to the actual introduction of the contact lenses forsterilization therein. In the event the user elects to fill thecontainer 22, with the catalyst in place therein, with the sterilizingsolution 32 prior to completing the placement of the contact lenses onthe lens support structure, or in the event of any other delay betweenthe beginning of contact of the catalyst with the solution and theactual placement of the lens carrying structure within the container 22,the breakdown of the sterilizing solution may be undesirablyaccelerated. Accordingly, the structure of the present invention helpsto insure a maximum time of contact of the lenses with a maximumstrength sterilizing solution initially, and avoids a prematurebreakdown of the sterilizing solution due to premature contact with thecatalyst or catalytic agent.

In a preferred embodiment illustrated in FIGS. 1-5, the means formounting the catalyst or catalytic agent within the lens supportstructure further comprises a carrier member 64 which has an enlarged,frame-like body. A disc-like catalyst carrying member or portion or"disc" 66 receives a quantity of catalyst material thereon; for example,by a sputter coating or other deposition process. The disc 66 iscomplementary in form for being releasably supported and mounted uponthe frame-like member 64 and, more particularly, within a complementaryopening 68 formed in the frame-like member 64.

Referring now briefly to FIGS. 4 and 5, it will be seen that theframe-like carrier member 64 includes a pair of resilient clip-likeengaging or locking members 70, 72. Cooperatively, an interior portionof the receptacle 60 includes complementary mating projections 74, 76for releasably engaging the resilient clip-like engaging members.Preferably the frame-like carrier member 64 also includes a projectingand preferably serrated gripping portion 80 which may be gripped by theuser for inserting and/or removing the same relative to the receptacle60. Alternatively, as shown in FIGS. 8 and 9, a separateinsertion/removal tool 82 may be provided for this purpose.

As best viewed in FIGS. 4 and 5, and in accordance with a preferred formof the invention, the catalyst disc 66 comprises a generally flat,disc-like member with a pattern of recesses and ridges 84 formed oneither face or surface thereof. These recesses and ridges generally aidin the process of manufacture and plating or coating of the disc member66 with catalyst. In order to secure the disc 66 within thecomplementary opening 68 in carrier 64, a projecting annular rim 86 isformed around the periphery of the disc 66. This rim 86 is engaged by aseries of tabs 88 which project from alternate sides of the opening 68in the embodiment illustrated in FIGS. 4 and 5, to provide for asnapping engagement therebetween when the disc is inserted from eitherside.

As best viewed in FIG. 2, the cap 30 is also provided with a ventingstructure designated generally by the reference numeral 90, which is thesame as the venting structure which is more fully disclosed anddescribed in copending application of R. W. Kanner et al, Ser. No.268,053 filed Nov. 7, 1988 which is commonly owned with thisapplication, and to which reference is invited concerning furtherdetails of the venting structure 90. Venting structure 90 permits thebuildup of a controlled amount of pressure due to the release of oxygenin the decomposition of the hydrogen peroxide. While this oxygen is notnecessarily vented through the venting structure 90, excess pressure inthe vessel is nonetheless prevented by the release of some amount of theresidual air and/or added oxygen in the space between the level offilling of the container with hydrogen peroxide and the cap.

Referring next to FIGS. 12-14, an alternative embodiment of the mountingmeans on the lens carrier structure for receiving a catalyst member orcatalytic agent is shown. In the embodiment of FIGS. 12-14, thecatalytic agent is similar if not identical in form to a presently usedcatalytic agent and comprises a generally hollow, and circular,cogwheel-shaped body 90. The body 90 is shaped to cooperatively fitwithin the bottom portion of the cylindrical container 22. To this endthe cogwheel-shaped body 90, as best viewed in FIGS. 13 and 14 has threeradially outwardly projecting spines 92 which serve to position the body90 relative to the interior walls of cylindrical container 22.

Departing from conventional practice, the body 90 is not placed withinthe container 22 by the user. Rather, the lens supporting structure 40is provided with an additional projecting catalyst-engaging portion 94which engages with and carries the catalyst member 90. In this regardthe catalyst member 90 has a small gap or opening 96 therein, whichimparts a somewhat resilient nature thereto, such that the catalystmember 90 may be resiliently expanded somewhat to interfit over theprojection 94 in a friction-type fit. In the embodiment illustrated inFIGS. 12-14, the projecting member 94 is a three-legged member havingthree substantially equal and equi-angularly spaced radial projections98, which are dimensioned for gripping engagement with an interiorsurface of the catalyst member 90. Accordingly, the catalyst member 90is engageable with the projection 94 so as to be carried upon the lenssupport structure 40, such that the catalyst will not be introduced intothe solution within container 22 prior to the introduction of the lensescarried on the lens support member. However, the catalytic agent isreadily removable for replacement by a user, as the catalytic agentbecomes exhausted in use.

As best viewed in FIGS. 6 and 7, the lens supporting structure alsoincludes means 100 defining a detent arrangement for holding each cover48, 49 detented in its respective fully open and fully closed positionsrelative to the associated lens support member 46, 47. In theillustrated embodiment, this detenting arrangement comprises aresiliently deflectable protruding member 102, which is formed in thebase 43, 45 at a position oppositely facing and aligned with an upperedge portion of the cover, at which portion the cover is hingedlycoupled with the base. This protruding resilient member is formed bycutting a pair of parallel elongate thin through openings 103 in thebase 43, 45 and forming a protruding, bump-like projection or portiontherebetween. Cooperatively, the cover member 45 includes at least oneprojection or bump-like portion 104, which engages this bump-likeportion during the opening and closing of the cover, and thereby definesa detented position of the cover to either side of the area or distanceover which the respective projections 102, 104 engage during opening andclosing thereof.

While particular embodiments of the invention have been shown anddescribed in detail, it will be obvious to those skilled in the art thatchanges and modifications of the present invention, in its variousaspects, may be made without departing from the invention in its broaderaspects, some of which changes and modifications being matters ofroutine engineering or design, and others being apparent only afterstudy. As such, the scope of the invention should not be limited by theparticular embodiment and specific construction described herein butshould be defined by the appended claims and equivalents thereof.Accordingly, the aim in the appended claims is to cover all such changesand modifications as fall within the true spirit and scope of theinvention.

The invention is claimed as follows:
 1. A catalyst support assembly foruse with apparatus for sterilization of contact lenses; said catalystsupport assembly comprising: a generally rectangular carrier configuredfor interfitting within a receptacle formed in a lens supporting meansfor contact lenses, a catalytic agent for neutralizing a hydrogenperoxide solution used in the sterilization of contact lenses carried bysaid carrier in such a manner that the catalytic agent is exposed at anexterior surface of said carrier for direct contact with hydrogenperoxide solution upon immersion of said catalyst support assembly in ahydrogen peroxide solution, retention means integrally formed on saidcarrier projecting outwardly of said carrier and configured for engagingthe receptacle formed in the lens supporting means for contact lenseswhen said carrier is inserted into said receptacle, thereby removablymounting said catalyst support assembly relative to the lens supportingmeans and preventing contact of the catalytic agent with the hydrogenperoxide sterilizing solution in a reaction vessel until the catalystsupport assembly mounted to the lens supporting means is immersed in asterilizing solution in the reaction vessel for beginning a sterilizingprocess, to thereby prevent premature breakdown of a sterilizingsolution prior to the introduction of contact lenses carried by the lenssupporting means for sterilization therein.
 2. A catalyst assemblyaccording to claim 1 wherein said carrier comprises a frame-shapedmember, with said retention means projecting integrally therefrom, saidframe-shaped member including a central through aperture, and whereinsaid catalytic agent comprises a receiving body coated with a catalyticmaterial and being disposed in said aperture formed in said frame-shapedmember.
 3. A catalyst assembly according to claim 1 wherein saidretention means comprises a pair of spaced resilient clip members formedon said carrier and adapted to engage the receptacle in a lenssupporting means with a snap fit.
 4. A catalyst assembly according toclaim 2 wherein said catalytic agent and said frame-shaped member areprovided with complementary interengaging snap fit means for mountingsaid catalyst element within aperture formed in said frame-like member.5. A catalyst assembly according to claim 1 further comprising aninsertion/removal tool having first engaging means formed for engagingand subsequently releasing said carrier for mounting relative to thereceptacle formed in the lens supporting means and second engaging meansformed for engaging said carrier for removal thereof from the receptacleformed in said lens supporting means.
 6. A catalyst support assembly foruse with apparatus for sterilization of contact lenses; said catalystsupport assembly comprising: a catalytic agent comprising acatalyst-receiving body of predetermined shape coated with a quantity ofcatalyst material for neutralizing a hydrogen peroxide solution used inthe sterilization of contact lenses; a carrier member having anenlarged, generally rectangular frame-shaped body portion, and whereinsaid catalyst-receiving body is shaped to be engaged and supported bysaid frame-shaped body portion in such a manner that the catalytic agentis exposed at an exterior surface of said carrier for direct contactwith hydrogen peroxide solution upon immersion of said catalyst supportassembly in the hydrogen peroxide solution; and means integrally formedwith said frame-shaped body portion for removably mounting said carriermember to lens supporting means, said engagement and support of saidcatalyst-receiving body by said frame-shaped body portion and saidmounting of said carrier member to lens supporting means being adaptedto prevent contact of the catalytic agent with a sterilizing solution ina reaction vessel until the lens supporting means with the catalystsupport assembly mounted thereto is placed in the reaction vessel forbeginning a sterilizing process, thereby to prevent premature breakdownof the sterilizing solution prior to the introduction of contact lensescarried by the lens supporting means for sterilization therein.
 7. Anassembly according to claim 6 wherein said means for removably mountingsaid carrier member to said lens supporting means further includesresilient clip engaging members, located and configured for releasablemating engagement with a lens supporting means.
 8. Apparatus accordingto claim 6 and further including an insertion/removal tool having firstengaging means formed for engaging and subsequently releasing saidframe-shaped body portion for mounting thereof relative to the lenssupporting means and second engaging means formed for engaging andretaining said frame-shaped body portion for removal thereof from thelens supporting means.